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5s Lean Presentation

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5s Lean Presentation

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This presentation is based on the book ”Succeeding with 5S” by Oskar Olofsson

Download the presentation together with templates and tools from world-class-manufacturing.com



This presentation is based on the book ”Succeeding with 5S” by Oskar Olofsson

Download the presentation together with templates and tools from world-class-manufacturing.com



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5s Lean Presentation

  1. 1. 5 Steps to a better workplace World-Class-Manufacturing.com
  2. 2. World-Class-Manufacturing.com 2 The purpose of 5S is to promote a safe and efficient work environment  5S is a method that uses five Japanese words which start with the letter S What is 5S? − Is it just another ”cleaning campaign”? − No – this is the end of one- shot cleaning campaigns!
  3. 3. World-Class-Manufacturing.com 3  How do we know if we have working 5S System? − If we do not have to clean a bit extra before an important visit
  4. 4. World-Class-Manufacturing.com 4  Improved safety − No items on the floor − Safety device in their right places − Less dust − Better overview − Less stress Reasons to implement 5S
  5. 5. World-Class-Manufacturing.com 5  Improved safety  Fewer breakdowns − Less wear from dust or grit in moving parts − Fewer errors from electronic systems due to bad environment Reasons to implement 5S
  6. 6. World-Class-Manufacturing.com 6  Improved safety  Fewer breakdowns  Better work environment − A clean and well functioning work place − Fix the unsafe and cluttered work stations Reasons to implement 5S
  7. 7. World-Class-Manufacturing.com 7  Improved safety  Fewer breakdowns  Better work environment  Less environmental impact − Leakages such as oil will easily be spotted − Using less floor space may reduce energy consumption Reasons to implement 5S
  8. 8. World-Class-Manufacturing.com 8  Improved safety  Fewer breakdowns  Better work environment  Less environmental impact  Fewer human errors − No outdated work instructions − Small but annoying faults are fixed − Fewer visual distractions when working − It should be easier to do it right than wrong! Reasons to implement 5S
  9. 9. World-Class-Manufacturing.com 9  Improved safety  Fewer breakdowns  Better work environment  Less environmental impact  Fewer human errors  May find problems earlier − When you clean a machine you inspect at the same time Reasons to implement 5S
  10. 10. World-Class-Manufacturing.com 10  Improved safety  Fewer breakdowns  Better work environment  Less environmental impact  Fewer human errors  May find problems earlier  No searching − Effective tools at the right place Reasons to implement 5S
  11. 11. World-Class-Manufacturing.com •11  Higher moral, motivation  Practical training in Lean for leaders and co-workers  Better impression  Easier to recruit good people Indirect gains with 5S Everyone should be able to work at a workplace that they can proudly present to others!
  12. 12. World-Class-Manufacturing.com 12 Think break  What would be the benefits for us if we implemented 5S?  What problems do we have today?  What could be root causes of today’s problem?
  13. 13. World-Class-Manufacturing.com 13 The five steps in 5S Seiri - Sorting Seiton - Organizing Seiso - Cleaning Step 5 – Discipline Seiketsu – Routines Step 1 Step 2 Step 3 Step 4 Step 5
  14. 14. World-Class-Manufacturing.com 14 Step 1 – Sorting  Sorting has two main purposes 1. Remove unnecessary objects 2. Reduce waste  Sorting is a team activity that will be carried out by the production and maintenance personnel together Step 1 – Sorting
  15. 15. World-Class-Manufacturing.com 15  Go through the whole plant − Machine and control positions − Work areas − Storage and common areas  Look for − Materials − Behind or under machines − Rejects − ”Forgotten” material Step 1 – Sorting Remove unnecessary objects
  16. 16. World-Class-Manufacturing.com 16 Go through the whole plant −Machine / control positions −Work area −Storage and common areas Look for −Materials −Tools Not in use Worn out or broken ”Custom-made” tools – made out of tape or steel wire Step 1 – Sorting Remove unnecessary objects
  17. 17. World-Class-Manufacturing.com 17 Go through the whole plant −Machine / control positions −Work area −Storage and common areas Look for −Materials −Tools −Spare parts Broken Surplus inventory Spare parts for machines no longer in use Step 1 – Sorting Remove unnecessary objects
  18. 18. World-Class-Manufacturing.com 18 Go through the whole plant −Machine / control positions −Work area −Storage and common areas Look for −Materials −Tools −Spare parts −Out-of-date Documentation Instructions Binders Manuals Common folders in the computer system Duplicates: digital and/or paper? Step 1 – Sorting Remove unnecessary objects
  19. 19. World-Class-Manufacturing.com 19 Go through the whole plant −Machine / control positions −Work area −Storage and common areas Look for −Materials −Tools −Spare parts −Out-of-date documentation −Computerized systems Step 1 – Sorting Remove unnecessary objects
  20. 20. World-Class-Manufacturing.com 20 Go through the whole plant −Machine / control positions −Work area −Storage and common areas Look for −Materials −Tools −Spare parts −Out-of-date Documentation −Bulletin board −Other stuff Outdated process equipment Et. cetera Step 1 – Sorting Remove unnecessary objects
  21. 21. World-Class-Manufacturing.com 21  Look at each object  Ask yourself: Do we need it at all? − If not – Discard it, or sell it  Ask yourself: Will we need it soon? − If not – Put it into proper storage (e.g. ”spare parts”) Step 1 – Sorting Remove unnecessary objects
  22. 22. World-Class-Manufacturing.com 22 Step 1 Seiri - Sort Each item to be discarded or corrected is marked with a red tag The red tag gives everyone the opportunity to speak up on the proposed action. A quarantine area can be created for the object you are unsure of. A red tag should never be up for more than 30 days. Date: Tagged by: Item description: Reason tagged: Tag No: Remove unnecessary objects
  23. 23. World-Class-Manufacturing.com Waste elimination 23 Step 1 – Sorting  The second purpose of sorting is to reduce waste and generate ideas for improvements  We will try to identify everything that is hindering us from working safely and efficiently
  24. 24. World-Class-Manufacturing.com 24  Identify:  Work instructions − Do we have them? − Are they up-to-date? − Are they in use? If not – why not? Step 1 – Sorting Waste elimination
  25. 25. World-Class-Manufacturing.com 25  Identify : Work instructions Safety −What measures should we take to eliminate the risk of fires and accidents? Remove clutter Improve unsafe electrical installations Replace broken safety devices Repair broken steps Step 1 – Sorting Waste elimination
  26. 26. World-Class-Manufacturing.com 26  Identify : Work instructions Safety Environment −What measures do we need to minimize or prevent damage to the environment? Step 1 – Sorting Waste elimination
  27. 27. World-Class-Manufacturing.com 27  Identify : Work instructions Safety Environment Tools and equipment −Anything missing? −Anything not working properly? −Anything in need of improvement? Step 1 – Sorting Waste elimination
  28. 28. World-Class-Manufacturing.com 28  Identify : Work instructions Safety Environment Tools and equipment Inconvenient work positions −Seating and work surfaces at the right heights? −...and adjustable for different shift workers? −Awkward angles for moving materials? Step 1 – Sorting Waste elimination
  29. 29. World-Class-Manufacturing.com 29  Identify : Work instructions Safety Environment Tools and equipment Inconvenient work positions Deferred maintenance −temporary repairs (like tape and steel wire) −obvious technical errors (like strange noises or smells, leakage, dangling parts) Step 1 – Sorting Waste elimination
  30. 30. World-Class-Manufacturing.com 30  Identify : Work instructions Safety Environment Tools and equipment Inconvenient work positions Deferred maintenance Improvement Proposals −review prior suggestions that were never implemented measures aimed at improving quality, operating purposes, procedures, controls, etc. Step 1 – Sorting Waste elimination
  31. 31. World-Class-Manufacturing.com 31 Step 1 – Sorting All identified waste items are marked with an red tag Date: Tagged by: Item description: Reason tagged: Tag No: Waste elimination
  32. 32. World-Class-Manufacturing.com 32 Step 1 – Sorting Machine tagged with errors and improvement suggestions
  33. 33. World-Class-Manufacturing.com 33 Date: Tagged by: Item description: Reason tagged: Tag No: Step 1 – Sorting Every tag refers to a 5S Sort list
  34. 34. World-Class-Manufacturing.com 34 Action plans after 5S sorting
  35. 35. World-Class-Manufacturing.com 35 Step 2 – Organizing Steg 1 Steg 2 Step 1 – Sorting Step 2 – Organizing The purpose is that everything that we regularly use should have a convenient placement − Tools should be kept at the point of use − No bending to pick up or move materials − Alter flow paths to improve efficiency
  36. 36. World-Class-Manufacturing.com 36 A good example
  37. 37. World-Class-Manufacturing.com This presentation is based on the book ”Succeeding with 5S” by Oskar Olofsson Download the full presentation at http://world-class- manufacturing.com 37

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